Custom Cable Assemblies

Connect-2 Technology has for many years provided a ‘custom make’ solution for small order requirements with low minimum order quantities of just 25pcs – and in some circumstances even lower, dependent on value.

There can be many situations when our service can prove invaluable, such as: -

· During product development cycles when designers may need to change the assembly to accommodate new features.
· Situations calling for cables with non-standard lengths.
· Unique interfacing requirements with mixed connector types not readily available elsewhere.
· High value products with low volume sales, etc.

Wide capabilities
We stock a large number of connector and cable types and have swift access to many more, enabling us to provide a quick and efficient service for virtually any type of custom cable requirement. In addition our technical and production staff are highly proficient in all termination methods (including solder, crimp, IDC, etc.) and of course all assemblies are manufactured under ISO 9001:2000.

How to make an enquiry
The simplest way is via our easy to use “Custom Cable Assemblies” form that is available here. This is a simple and clear excel spreadsheet which you can enter all your information into, save a copy and email or fax a copy to us. Within a couple of days we will send you a detailed quotation containing full assembly specifications, price and delivery details.

Coiled (Curly) Leads

Over the last year we have seen a big increase in demand for custom designed coiled leads for both electrical and electronic applications. Our Far East partner manufactures all coiled cables to exact customer specifications with lead-times typically of between 8 to 10 weeks for initial stocks after which ongoing requirements can be supplied via kanban or order schedule agreements to facilitate timely stock replenishment.

Volume requirements can be as low as just 200pcs depending on the bulk cable stock requirements. Pricing is of course highly competitive. A recent example is a car power adaptor cable which had a 2amp fused car cigarette lighter plug at one end and a fully moulded 2.1mm DC plug at the other end of a 2-core, 24AWG, PU 1.5 metre curly cable with a minimum order quantity of 500pcs and a cost of sub- £2.00 each.

As with all products from Connect-2 Technology, Far East production is solely from an ISO 9000 qualified manufacturer who in addition also provides full RoHS compliance.

Whatever your particular requirement may be, Connect-2 Technology is certain to provide the solution. We can supply custom manufactured electrical and electronic coiled leads for many application areas, which include (but not limited to): -

· Communications
· Industrial Equipment
· Control
· Computer
· Audio / Video
· Power Management
· Environmental
· Test & Data Collection
· Gaming
· Medical

As always, if you would like a quick quote please send your drawing/specifications here.

Molex KK Wiring Assemblies

The Molex KK range of connectors is still amongst the most widely used by many of our customers for thousands of different wire-to-board and board-to-board applications. Over the last 12 years we have manufactured millions of assemblies utilising this series of “building block” connectors to create thousands of different configurations. The applications in which they have been used are vast and span most electronic sectors.

As the Molex KK interconnection system can provide all the options necessary to compliment PC board interconnection design requirements and provide a combination of reliability, versatility and cost performance the range is still extremely popular today.

Connect-2 Technology holds a wide range of housing stock and terminals in both 2.54mm (0.1”) and 3.96mm (0.156”) centres. All terminals are crimped using semi-automatic equipment to provide the most accurate and consistent terminations possible.

As always, if you would like a quick quote please send your drawing/specifications here.

Pipeline Pig

A major oil and gas pipeline inspection company has placed specialist harness assembly work, via one of our existing CEM customers.

Connect-2 Technology was chosen based on our level of expertise and our technical abilities to undertake the project. This high value work utilises very expensive 'high reliability' connectors and involves precision assembly with gas-tight connections requiring a high degree of expertise to complete. The assemblies are for use within 'smart pigs' used to inspect the pipeline from the inside and record data for later analysis.

As always, if you would like a quick quote please send your drawing/specifications here.

Arc Weld Robot

Towards the end of 2006 we undertook a project to produce the panel and associated wiring for a control unit used for oil pipe welding robots, destined for use in Dubai. After the initial development stage by our technical team our dedicated sub-assembly section completed the project on-time and to the required build standard.

As always, if you would like a quick quote please send your drawing/specifications here.

US Freight Monster

One of our long-standing customers was subject to a takeover last year by a US company, due to their expertise in specialist control systems.

This resulted in a large increase in demand, so they turned to Connect-2 Technology to provide DIN rail wiring assemblies which form part of the diesel power control unit used on the latest US container freight trains. The trains themselves are monsters at up to 2.5km (over 1.5 miles) in length and hauling container wagons, often stacked two high! Connect-2's technical team converted the customers existing drawings and specifications to our own 'in-house' requirements and produced the initial samples to meet the customer deadline in record time, enabling swift transition to our production unit for ongoing manufacture.

As always, if you would like a quick quote please send your drawing/specifications here.

Special Projects

Connect-2 Technology continues to grow from strength to strength! Since our inception in 1995 we have constantly increased our range of services to cover the growing requirements of our customers.

Over the past couple of years we have gradually expanded our dedicated 'Special Projects Team' to enable efficient handling of a diverse range of customer requirements beyond the scope of general connection assemblies. Our specialist technicians can now provide the expertise required to take forward a variety of sub-assembly and panel building tasks to exacting customer specifications. Providing an efficient, reliable and overall cost/time saving solution allows customers to concentrate effort and resources to greater effect elsewhere within their business. Connect-2 Technology manufactured sub-assemblies, wiring and harnesses are now found in a wide variety of electrical/electronic equipment globally - even under Kylie's bum!

Kylie!! - just in case you were curious! We have been manufacturing a large harness for one of our long established customers for sometime. It was only recently that we discovered that it was in fact the control loom for a 'rodeo bull' ride popular in certain night clubs. And, the bull in question was used for a publicity video for 'The Most Erotic Lingerie Company In The World' featuring the one and only Kylie - and who said engineering was boring.

Watch the video here.

As always, if you would like a quick quote please send your drawing/specifications here.

Small Panel Builds

For many years Connect-2 Technology has provided customers with a dedicated small panel building service. We have access to a wide range of panel components (switches, indicators, DIN assemblies, test points, etc) as well as convenient approved sources for metal work and various coatings. Our dedicated assembly building team provides a significant resource for all your panel and box assembly builds.

Typical Application Areas:

· Home Care Products
· Multimedia
· Security & Alarms
· Fire Protection Equipment
· Airport Baggage Equipment
· Environmental Equipment & Controls
· Industrial Instruments
· Power Control Equipment

As always, if you would like a quick quote please send your drawing/specifications here.

HARWIN M80 Semi-Auto Tooling Investment

Due to increasing demand for assemblies manufactured with the Harwin M80 Datamate range of wire-to-board connectors, we have made a significant investment in a custom-manufactured semi-auto termination machine (the first in the UK). The 2mm pitch connector system is now widely used for military, computer, aerospace, medical and telecommunications applications due to its high levels of performance and reliability.

The range utilises a 'barrel' crimp which requires precision termination to maintain connection integrity when mated. The design provides maximum signal transmission resulting in no data loss. Normally the only termination option available is with hand-tooling which is not suitable for medium to high volumes. For highly reliable Harwin Datamate M80 assemblies, whether low, medium or high volume, remember to contact Connect-2 Technology here.

Molex Micro Connectors1.25mm Pitch

Now a very popular range of Wire-to-Board signal connectors for use with both Through-hole and SMT headers. Designed for high-density applications. Housings are single-row, 2-15 circuits, crimp terminals use 26~28AWG wire.

· Applications:
· Medical
· Multimedia
· Security & Alarms
· Computer Peripherals
· Environmental Equipment & Controls
· Industrial Instruments

Connect-2 Technology has produced assemblies using this Molex range, for a wide scope of applications both large and small, for over five years. Our fully automatic equipment provides customers with high reliability and a consistent quality of termination.

As always, if you would like a quick quote please send your drawing/specifications here.

Far East or UK?

Connect-2 Technology is a highly successful strategic manufacturing partner with a proven track record capable of attracting and maintaining prestigious contracts whilst at the same time providing a reliable and efficient service to Small & Medium-sized Enterprises (SME’s). Utilising our excellent UK manufacturing facilities and technical ‘know-how’ combined with Far East manufacturing enables our customers to benefit from both.

Our UK manufacturing sites can provide prototype, low and medium production volumes, whilst additional Far East facilities provide medium and high volume production offering customers scope for ongoing cost reduction.

Cost Reduction

European electronics manufacturers need to constantly evaluate product cost and the effectiveness of their supply chain in order to maintain a competitive edge. The sourcing of components and sub-assemblies such as cable assemblies, wiring harnesses and electronic assemblies from “low labour cost” regions such as the Far East are critical and can provide significant cost benefits.

For many years Connect-2 Technology has had an established relationship with a number of manufacturers in both Taiwan and China, providing a wide range of cable assemblies, electronic sub-assemblies and components. Our partners are fully ISO9000/UL approved and our own internal quality inspection procedures ensure customer specifications are adhered to throughout the product lifetime, providing you with protected access to the benefits of Far East sourcing.